Taking a new product from the design stage to large-scale production in a profitable, efficient manner can challenge the processes of even the most advanced companies. Lapses in these processes drive up the cost of new products, and hinder their launch into the marketplace. Effective Transition from Design to Production provides an expeditious roadmap that considers every phase of production. It identifies customer requirements, discusses product concept, and covers master scheduling and risk analysis, as well as design considerations, prototypes, and tooling essentials. Among other things, it also explains how to identify and augment facility requirements, initiate production ramp up, evaluate packaging, and institute defect control.
Takes an Integrative Approach that Allows Managers to Understand the Big Picture
As the author introduces and explains each stage, he also offers guidance as to when to involve outside parties including potential providers of raw materials and subcontractors who may take part in the production and assembly process. He presents the seven stages of the production process- system design, detailed design, manufacturing planning, production readiness, low rate initial production, and production-in sequential order, examining how each one leads to the other. This allows readers to not only grasp the basic concepts crucial for success at each stage, but also to visualize the big picture so that they can anticipate problems, eliminate inefficiency, and make informed managerial decisions.
Introduction Proposal/Contract General Discussion Proposal Support Identify Customer Requirements Determine Product Concept Determine Commonality Request for Deviations from Customer Requirements Risk Analysis/Risk Mitigation Design to Cost Master Schedule Determine Production Philosophy and Location Simulation Analysis for Producibility Simulation Analysis for Factory Assembly Tooling Forecasts - Assess Assembly Tooling Requirements New or Modified Production Equipment System/Conceptual Design Conduct Prelimary Design to Cost Analysis Assembly Process Methodology Develop Tooling Concepts Develop Manufacturing Plan/Flow Identify New Manufacturing Technologies Determine Product-Packaging Requirements Develop Prototype Assembly Tooling Conduct Facilities and Analysis Determine Logistical Support Requirements Determine Capital Equipment Requirements Determine Test Philosophy Determine Quality Assurance Requirements Identify Human Resource Requirements Meetings Detailed Design New Production Process Development Assembly/Process Methodology Design to Cost Conduct Parts Obsolescence Study Design for Production Design for Manufacturing and Assembly (DFMA)/Design for the Environment (DFE) Conduct Cross-Functional Design Reviews Bill of Material - Create Detailed Indentured Bill of Material Assembly Simulation Select Subcontractors/Vendors/Selection Process Determine Exit Criteria for Design Output to Manufacturing Create Detailed Manufacturing Plan/Flow Lean Factory Design/Balanced Flow Develop Configuration Management Plan Documentation Media Method Conduct Product Design Documentation Release Prepare Test Integration Plan Create Test Hardware and Software Manufacturing Planning & Processes/Prototype Development/Test Development Transition New Production Processes Determine Facility Requirements Finalize Assembly Methodology Determine Tool Design and Fabrication Requirements Ergonomics Transition to a Contract Manufacturing Facility Vendor Implementation Write Software Programs for Manufacturing Equipment Assembly Tooling Finalize New Production Processes Conduct Line Balancing Analysis Metrics Determine Inventory System Based on Contractual Type Staffing Plan Tool Control Finalize Manufacturing Plan/Flow Conduct Prototype Documentation Planning Determine Capital Requirements Create Inventory System Finalize Production Plan Conduct a Preliminary Production Readiness Review Test Integration Manufacturing Plan Checklists Production Readiness Production Readiness Implement Line Stock Configuration Management Create Change Control Board Tooling Verification Support Transition to Production Process Create Prototype Routing and Planning Develop Change Control Board Protocol Conduct Prototype Kitting Coordinate Configuration Management with Vendors Develop Quality Assurance Requirements/Buy-Off Train Production Staff Build Prototype Low Rate Initial Production (LRIP) Introduction to LRIP Obtain and Implement Production Tooling Update Tooling Documentation Calibration and Maintenance Update Drawing Documentation Update Planning Documentation Implement Kitting Plans Update Test Fixtures and Software for Production Hardware Staffing Plan Finalized Build First Article Create a Master Schedule Documentation Changes First Article Buy-Off Begin Low Rate Initial Production Production Ramp-Up Production Build Production Units - Ramp Up to Full Production Other Areas for Concern Data Loss Bathtub Issues Defect Control The Hidden Factory The Experience Level of Manufacturing and Producibility Engineering Personnel Appendix A Quality Functional Deployment Appendix B Six Sigma Tools Appendix C Design for Manufacturing Appendix D Vendor Assessment Forms Appendix E Production Readiness Check Sheets / Evaluation Forms Appendix F Design for the Environmental Guide References